Cushions having voids in a lower surface

ABSTRACT

Mattresses, cushions, and body-support mats or pads are disclosed. Polymer(s) at least partially define a length, width and depth, the depth extending from an upper surface proximate to where a user rests to a lower surface opposite the upper surface. Voids in the polymer traverse at least a portion of the width. The plurality of voids are located at the lower surface and/or the upper surface and are defined by polymer walls and wall(s) of polymer walls define each polymer foot of polymer feet. A first region of a plurality of lower surface regions includes at least one foot of the plurality of polymer feet that has a first size. A second region of the plurality of lower surface regions includes at least one other foot having a second size. The at least one other foot spans a greater distance along the length than the at least one foot.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a by-pass continuation of PCT InternationalApplication No. PCT/US2022/021194, filed on Mar. 21, 2022, and entitledMattresses, Cushions, and Body-Support Pads or Mats Having Voids andGrooves On At Least One Surface, which claims priority benefit of U.S.Provisional Patent Application No. 63/164,011, filed Mar. 22, 2021, andentitled Foam Mattresses, Foam Cushions, and Foam Body-Support Pads orMats, of U.S. Provisional Patent Application No. 63/179,813, filed Apr.26, 2021, and entitled Mattresses, Cushions, and Body-Support Pads orMats Having Polymer Feet, of U.S. Provisional Patent Application No.63/210,306, filed Jun. 14, 2021, and entitled Mattresses, Cushions, andBody-Support Pads or Mats Having Voids and Grooves, and of U.S.Provisional Patent Application No. 63/241,089, filed Sep. 6, 2021, andentitled Mattresses, Cushions, and Body-Support Pads or Mats HavingVoids and Grooves on At Least One Surface, the entire contents of all ofwhich are hereby expressly incorporated by reference in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to mattresses, cushions, andbody-support pads or mats and more particularly to mattresses, cushionsand body-support pads or mats having voids and grooves on at least onesurface.

BACKGROUND

Consumers often purchase and utilize bed assemblies with adjustablebases. Bed assemblies with adjustable bases can be convenient and enablea user to adjust the base of the bed so that a mattress supporting theuser and positioned on top of the base can support the user at a desiredergonomic position. Movement of the adjustable base will cause amattress located on top of the adjustable base to shift or move. Varioustechniques have been used to control mattress movement so that themattress maintains its position centered on the adjustable base. Forexample, retainer bar assemblies may be secured to the foot portion ofthe adjustable base and/or at the head portion of the adjustable base inorder to prevent the mattress from sliding or lifting in response to theadjustable base inclining or folding. Various other fixation devices arealso used to limit movement of the mattress relative to the adjustablebase and to keep the mattress in place so that a user does not have toreadjust the mattress positioning when the adjustable base inclines orfolds. Although this provides many advantages, these measures intendedto limit the movement of the mattress and keep the mattress in place mayalso cause compression near the midpoint or pivot point of the mattress.In particular, inclining the head portion of the adjustable base and/orthe foot portion of the adjustable base past a certain angle may causethe midpoint or pivot point of the mattress to bunch in the mattressmaterial due to the folding or compression of the mattress.

When the adjustable base is set to incline at a relatively large angle,the bunching of the material near the midpoint or pivot point can leadto ridges on the surface of the mattress that become more pronounced thelarger the incline of the mattress. These ridges and bunching can feeluncomfortable to a user resting on the mattress. In some cases, theridges formed from the mattress bunching may not be as soft as the restof the mattress, and this harder surface could potentially even resultin a user developing sores or bruising in the regions of the body thatare in contact with the ridges. Thus, a need exists to reduce thelikelihood that ridges will form on the surface of the mattress when themattress is compressed or folded as a result of inclining the adjustablebase.

Another disadvantage that results from the ridges formed in a mattressdue to compression or folding relates to mattress packing. One processoften used to facilitate transport of a mattress is to fold or roll themattress into a box for transportation and shipment. The rolling orfolding can also result in ridges forming on the surface of themattress. When the mattress is rolled or folded the ridges may cause airpockets that can take up space. These air pockets may limit the abilityof the mattress to be folded or packed into a smaller box or package.Thus, a need exists to reduce the likelihood that ridges will form onthe surface of the mattress, which may cause air pockets to form duringfolding, rolling, and packing.

While certain aspects of conventional technologies have been discussedto facilitate disclosure of the invention, Applicants in no way disclaimthese technical aspects, and it is contemplated that the claimedinvention may encompass one or more of the conventional technicalaspects discussed herein.

In this specification, where a document, act or item of knowledge isreferred to or discussed, this reference or discussion is not anadmission that the document, act or item of knowledge or any combinationthereof was, at the priority date, publicly available, known to thepublic, part of common general knowledge, or otherwise constitutes priorart under the applicable statutory provisions; or is known to berelevant to an attempt to solve any problem with which thisspecification is concerned.

SUMMARY

Shortcomings of the prior art are overcome and additional advantages areprovided through improved mattress, cushions, and body-support pads ormats disclosed herein. In particular, disclosed herein are mattresses,cushions, and body-support pads or mats that include a polymer such as apolymeric foam (e.g. Toluene Diisocyanate (TDI) foam orMethylenediphenyl diisocyanate (MDI) foam), or an elastomer. The polymermay include a first plurality of voids, gaps, or grooves located on theunderside or lower surface of the polymer. Advantageously, the firstplurality of voids, gaps, or grooves may allow for the polymer to foldor bend without causing the bunching and ridges on the top or restingsurface of the mattress that is the side opposite the bottom side orunderside that includes the first plurality of voids, gaps, or grooves.The polymer may further include a second plurality of voids, gaps, orgrooves located on the topside or upper surface of the polymer.Advantageously, the second plurality of voids, gaps, or grooves mayfurther allow for the polymer to fold or bend without causing thebunching and ridges on the top or resting surface of the mattress thatis the side opposite the bottom side or underside that includes thefirst plurality of voids, gaps, or grooves.

It is also contemplated that the improved mattresses, cushions, andbody-support pads or mats may prove useful in addressing other problemsand deficiencies in a number of technical area. Therefore, the disclosedmattresses, cushions, and body-support pads or mats should notnecessarily be construed as limited to addressing any of the particularproblems or deficiencies discussed herein.

Certain embodiments of the presently disclosed mattresses, cushions, andbody-support pads or mats have several features, no single one of whichis solely responsible for their desirable attributes. Without limitingthe scope of the mattresses, cushions, and body-support pads or mats asdefined by the claims that follow, their more prominent features willnow be discussed briefly. After considering this discussion, andparticularly after reading the section of this specification entitled“Detailed Description,” one will understand how the features of thevarious embodiments disclosed herein provide a number of advantages overthe current state of the art.

In one aspect, disclosed herein is a mattress that includes polymerdefining a length and a width of the mattress. The polymer spans a depththat is perpendicular to the length and the width of the mattress andextends from an upper surface of the polymer that is proximate to wherea user rests to a lower surface of the polymer, where the lower surfaceis opposite the upper surface that is proximate to where the user rests.The mattress further includes a first plurality of voids in the polymerthat traverse at least a portion of the width of the mattress, where thefirst plurality of voids are located at the lower surface, and where thefirst plurality of voids are defined by polymer walls of the polymer.The mattress also includes a first plurality of polymer feet, whereineach polymer foot of the first plurality of polymer feet is defined byone or more walls of the polymer walls. Additionally, the mattressincludes a plurality of lower surface regions, where a first region ofthe plurality of lower surface regions includes multiple feet of thefirst plurality of polymer feet and at least one foot having a firstsize, and a second region of the plurality of lower surface regionsincludes at least one other foot of the first plurality of polymer feetthat has a second size. Further, the at least one other foot having thesecond size spans a greater distance along the length of the mattressthan the at least one foot having the first size.

In another aspect disclosed herein is a cushion that includes polymerdefining a length and a width of the cushion. The polymer spans a depththat is perpendicular to the length and the width of the cushion andextends from an upper surface of the polymer that is proximate to wherea user rests to a lower surface of the polymer, where the lower surfaceis opposite the upper surface that is proximate to where the user rests.The cushion further includes a first plurality of voids in the polymerthat traverse at least a portion of the width of the cushion, where thefirst plurality of voids are located at the lower surface, and where thefirst plurality of voids are defined by polymer walls of the polymer.The cushion also includes polymer feet, wherein each polymer foot of thepolymer feet is defined by one or more walls of the polymer walls.Additionally, the cushion includes a plurality of lower surface regions,where a first region of the plurality of lower surface regions includesmultiple feet of the polymer feet and at least one foot having a firstsize, and a second region of the plurality of lower surface regionsincludes at least one other foot of the polymer feet that has a secondsize. Further, the at least one other foot having the second size spansa greater distance along the length of the cushion than the at least onefoot having the first size.

In another aspect disclosed herein is a body-support pad or mat thatincludes polymer defining a length and a width of the body-support pador mat. The polymer spans a depth that is perpendicular to the lengthand the width of the body-support pad or mat and extends from an uppersurface of the polymer that is proximate to where a user rests to alower surface of the polymer, where the lower surface is opposite theupper surface that is proximate to where the user rests. Thebody-support pad or mat further includes a first plurality of voids inthe polymer that traverse at least a portion of the width of thebody-support pad or mat, where the first plurality of voids are locatedat the lower surface, and where the first plurality of voids are definedby polymer walls of the polymer. The body-support pad or mat alsoincludes polymer feet, wherein each polymer foot of the polymer feet isdefined by one or more walls of the polymer walls. Additionally, thebody-support pad or mat includes a plurality of lower surface regions,where a first region of the plurality of lower surface regions includesmultiple feet of the polymer feet and at least one foot having a firstsize, and a second region of the plurality of lower surface regionsincludes at least one other foot of the polymer feet that has a secondsize. Further, the at least one other foot having the second size spansa greater distance along the length of the body-support pad or mat thanthe at least one foot having the first size.

In another aspect, disclosed herein is a mattress that includes polymerdefining a length and a width of the mattress. The polymer spans a depththat is perpendicular to the length and the width of the mattress andextends from an upper surface of the polymer that is proximate to wherea user rests to a lower surface of the polymer, where the lower surfaceis opposite the upper surface that is proximate to where the user rests.The mattress further includes a first plurality of voids in the polymerthat traverse at least a first portion of the width of the mattress,where the first plurality of voids are located at the lower surface, andwhere the first plurality of voids are defined by polymer walls of thepolymer. The mattress also includes a first plurality of polymer feet,wherein each polymer foot of the first plurality of polymer feet isdefined by one or more walls of the polymer walls. Additionally, themattress includes a plurality of lower surface regions, where a firstregion of the plurality of lower surface regions includes multiple feetof the first plurality of polymer feet and at least one foot having afirst size, and a second region of the plurality of lower surfaceregions includes at least one other foot of the first plurality ofpolymer feet that has a second size. Further, the at least one otherfoot having the second size spans a greater distance along the length ofthe mattress than the at least one foot having the first size. Themattress further includes a second plurality of voids in the polymerthat traverse at least a second portion of the width of the mattress,where the second plurality of voids are located at the upper surface,and where the second plurality of voids are defined by the polymer wallsof the polymer. The mattress also includes a second plurality of polymerfeet, wherein each polymer foot of the second plurality of polymer feetis defined by one or more walls of the polymer walls. Additionally, themattress includes a plurality of upper surface regions, where a firstregion of the plurality of upper surface regions includes multiple feetof the second plurality of polymer feet and at least one foot having athird size, and a second region of the plurality of upper surfaceregions includes at least one other foot of the second plurality ofpolymer feet that has a fourth size. Further, the at least one otherfoot having the fourth size spans a greater distance along the length ofthe mattress than the at least one foot having the third size.

In another aspect, disclosed herein is a cushion that includes polymerdefining a length and a width of the cushion. The polymer spans a depththat is perpendicular to the length and the width of the cushion andextends from an upper surface of the polymer that is proximate to wherea user rests to a lower surface of the polymer, where the lower surfaceis opposite the upper surface that is proximate to where the user rests.The cushion further includes a first plurality of voids in the polymerthat traverse at least a first portion of the width of the cushion,where the first plurality of voids are located at the lower surface, andwhere the first plurality of voids are defined by polymer walls of thepolymer. The cushion also includes a first plurality of polymer feet,wherein each polymer foot of the first plurality of polymer feet isdefined by one or more walls of the polymer walls. Additionally, thecushion includes a plurality of lower surface regions, where a firstregion of the plurality of lower surface regions includes multiple feetof the first plurality of polymer feet and at least one foot having afirst size, and a second region of the plurality of lower surfaceregions includes at least one other foot of the first plurality ofpolymer feet that has a second size. Further, the at least one otherfoot having the second size spans a greater distance along the length ofthe cushion than the at least one foot having the first size. Thecushion further includes a second plurality of voids in the polymer thattraverse at least a second portion of the width of the cushion, wherethe second plurality of voids are located at the upper surface, andwhere the second plurality of voids are defined by the polymer walls ofthe polymer. The cushion also includes a second plurality of polymerfeet, wherein each polymer foot of the second plurality of polymer feetis defined by one or more walls of the polymer walls. Additionally, thecushion includes a plurality of upper surface regions, where a firstregion of the plurality of upper surface regions includes multiple feetof the second plurality of polymer feet and at least one foot having athird size, and a second region of the plurality of upper surfaceregions includes at least one other foot of the second plurality ofpolymer feet that has a fourth size. Further, the at least one otherfoot having the fourth size spans a greater distance along the length ofthe cushion than the at least one foot having the third size.

In another aspect, disclosed herein is a body-support pad or mat thatincludes polymer defining a length and a width of the body-support pador mat. The polymer spans a depth that is perpendicular to the lengthand the width of the body-support pad or mat and extends from an uppersurface of the polymer that is proximate to where a user rests to alower surface of the polymer, where the lower surface is opposite theupper surface that is proximate to where the user rests. Thebody-support pad or mat further includes a first plurality of voids inthe polymer that traverse at least a first portion of the width of thebody-support pad or mat, where the first plurality of voids are locatedat the lower surface, and where the first plurality of voids are definedby polymer walls of the polymer. The body-support pad or mat alsoincludes a first plurality of polymer feet, wherein each polymer foot ofthe first plurality of polymer feet is defined by one or more walls ofthe polymer walls. Additionally, the body-support pad or mat includes aplurality of lower surface regions, where a first region of theplurality of lower surface regions includes multiple feet of the firstplurality of polymer feet and at least one foot having a first size, anda second region of the plurality of lower surface regions includes atleast one other foot of the first plurality of polymer feet that has asecond size. Further, the at least one other foot having the second sizespans a greater distance along the length of the body-support pad or matthan the at least one foot having the first size. The body-support pador mat further includes a second plurality of voids in the polymer thattraverse at least a second portion of the width of the body-support pador mat, where the second plurality of voids are located at the uppersurface, and where the second plurality of voids are defined by thepolymer walls of the polymer. The body-support pad or mat also includesa second plurality of polymer feet, wherein each polymer foot of thesecond plurality of polymer feet is defined by one or more walls of thepolymer walls. Additionally, the body-support pad or mat includes aplurality of upper surface regions, where a first region of theplurality of upper surface regions includes multiple feet of the secondplurality of polymer feet and at least one foot having a third size, anda second region of the plurality of upper surface regions includes atleast one other foot of the second plurality of polymer feet that has afourth size. Further, the at least one other foot having the fourth sizespans a greater distance along the length of the body-support pad or matthan the at least one foot having the third size.

These and other features and advantages of the disclosure and inventionswill become apparent from the following detailed description of thevarious aspects of the invention taken in conjunction with the appendedclaims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects described herein are particularly pointed out and distinctlyclaimed as examples in the claims at the conclusion of thespecification. The foregoing and other objects, features, and advantagesof the disclosure are apparent from the following detailed descriptiontaken in conjunction with the accompanying drawings, which are notnecessarily drawn to scale, wherein:

FIG. 1 depicts an elevational perspective view of a mattress andadjustable base, according to the prior art;

FIG. 2 depicts an elevational perspective view of a polymer of amattress and an adjustable base, according to the present disclosure;

FIG. 3A depicts an elevational perspective view of a polymer of amattress and an adjustable base, according to the present disclosure;

FIG. 3B depicts an elevational perspective view of the polymer of themattress and adjustable base of FIG. 3A with an additional void at thefoot portion of the polymer of the mattress, according to the presentdisclosure;

FIG. 3C depicts an elevational perspective view of the polymer of themattress and adjustable base of FIG. 3A with a plurality of additionalvoids at the foot portion of the polymer of the mattress, according tothe present disclosure;

FIG. 4A depicts a bottom view of a polymer of a mattress with aplurality of voids extending the width of the polymer of the mattress,according to the present disclosure;

FIG. 4B depicts a bottom view of the polymer of the mattress of FIG. 4Awith an additional void extending the length of the polymer of themattress, according to the present disclosure;

FIG. 4C depicts a bottom view of the polymer of the mattress of FIG. 4Awith multiple voids extending the length of the polymer of the mattress,according to the present disclosure;

FIG. 4D depicts a bottom view of the polymer of the mattress of FIG. 4Awith multiple voids extending the length of the polymer of the mattress,according to the present disclosure;

FIG. 4E depicts a bottom view of the polymer of the mattress of FIG. 4Awith multiple voids extending the length of the polymer of the mattress,according to the present disclosure;

FIG. 5A depicts a side view of a polymer of a mattress with a pluralityof voids along the length of the polymer of the mattress, according tothe present disclosure;

FIG. 5B depicts a side view of a polymer of a mattress with a pluralityof voids along the length of the polymer of the mattress, according tothe present disclosure;

FIG. 5C depicts a side view of a polymer of a mattress with a pluralityof voids along the length of the polymer of the mattress, according tothe present disclosure;

FIG. 5D depicts a side view of a polymer of a mattress with a pluralityof voids along the length of the polymer of the mattress, according tothe present disclosure;

FIG. 6A depicts a side view of a polymer of a mattress with multiplegrooves situated along the width of the polymer of the mattress,according to the present disclosure;

FIG. 6B depicts a side view of a polymer of a mattress with multiplegrooves situated along the width of the polymer of the mattress,according to the present disclosure;

FIG. 6C depicts a side view of a polymer of a mattress with multiplegrooves situated along the width of the polymer of the mattress,according to the present disclosure;

FIG. 7 depicts a side view of a polymer of a mattress with a pluralityof dual-sided voids along the length of the polymer of the mattress,according to the present disclosure; and

FIG. 8 depicts a side view of a polymer of a mattress with a pluralityof dual-sided voids along the length of the polymer of the mattress,according to the present disclosure.

DETAILED DESCRIPTION

Aspects of the present disclosure and certain features, advantages, anddetails thereof, are explained more fully below with reference to thenon-limiting embodiments illustrated in the accompanying drawings.Descriptions of well-known materials, fabrication tools, processingtechniques, etc., are omitted so as to not unnecessarily obscure thedetails of the inventions. It should be understood, however, that thedetailed description and the specific example(s), while indicatingembodiments of inventions of the present disclosure, are given by way ofillustration only, and are not by way of limitation. Varioussubstitutions, modifications, additions and/or arrangements within thespirit and/or scope of the underlying inventive concepts will beapparent to those skilled in the art from this disclosure.

Approximating language, as used herein throughout disclosure, may beapplied to modify any quantitative representation that could permissiblyvary without resulting in a change in the basic function to which it isrelated. Accordingly, a value modified by a term or terms, such as“about” or “substantially,” is not limited to the precise valuespecified.

Described herein are mattresses, cushions and body-support pads or matsthat include a polymer. The polymer defines a length and a width of therespective mattress, cushion, or body-support pad or mat. Further, thepolymer spans a depth that is perpendicular to the length and the width,where the depth extends from an upper surface of the polymer that isproximate to where a user rests to a lower surface of the polymer thatis opposite the upper surface. The polymer includes a first plurality ofvoids, gaps, or grooves that traverse a portion of the width and/or thelength of the respective mattress, cushion, or body-support pad or mat,where the first plurality of voids, gaps, or grooves are located in thelower surface and are defined by polymer walls of the polymer. The firstplurality of voids, gaps, or grooves in the polymer allow for therespective mattress, cushion, or body-support pad or mat to fold or bendin a manner that reduces bunching and ridges that typically form on thetop or resting surface that supports the user when folding/bending therespective mattress, cushion, or body-support pad or mat. The firstplurality of voids, gaps, or grooves in the polymer also allow for therespective mattress, cushion, or body-support pad or mat to be packed ina reduced volume and/or weight, which can lower shipping cost.

The polymer may further include a second plurality of voids, gaps, orgrooves located in the upper surface of the polymer that traverse aportion of the width and/or the length of the respective mattress,cushion, or body-support pad or mat. The second plurality of voids,gaps, or grooves are located in the upper surface and are defined bypolymer walls of the polymer. Advantageously, the second plurality ofvoids, gaps, or grooves may further allow for the polymer to fold orbend without causing the bunching and ridges on the top or restingsurface of the respective mattress, cushion, or body-support pad or matthat is the side opposite the lower surface that includes the firstplurality of voids, gaps, or grooves. The second plurality of voids,gaps, or grooves in the polymer also allow for the respective mattress,cushion, or body-support pad or mat to be packed in a reduced volumeand/or weight, which can lower shipping cost.

For instance, as depicted in FIG. 1 , existing mattresses such asmattress 100 that are folded or bent in response to an adjustablebase/frame 150 being inclined typically causes bunching or ridges 199near the midpoint or pivot point of the mattresses as depicted inmattress 100. The bunching and ridges 199 can cause discomfort andprovide a hardened surface that can cause bedsores or bruising to auser.

In contrast, mattresses, cushions, and body-support pads or mats thatinclude polymers having a plurality of voids, gaps and/or grooves thattraverse a portion of the width and/or length of the mattress reduce thelikelihood that ridges or bunching will form on the upper/restingsurface from folding or bending the mattress.

Referring now to FIG. 2 , a mattress 200 and adjustable base/frame 250are depicted. In particular, the mattress 200 includes one or morepolymer. Although not depicted in FIG. 2 , the one or more polymer maybe at least partially enclosed by a mattress cover according to variousembodiments. For instance, the one or more polymer may be fully enclosedby the mattress cover. Further, the mattress cover may form theuppermost surface of the mattress that is proximate to where a user ofthe mattress rests as well as the bottommost surface that is in contactwith the base 250. According to some embodiments, a fire-resistantmaterial may be located near the uppermost surface, and in particularlocated between the mattress cover and the upper surface of the one ormore polymer. According to various embodiments, the mattress cover mayinclude a fabric that has a stretch capacity within a range of about 1%stretch to about 50% stretch, or more particularly within a range ofabout 10% stretch to about 40% stretch, 20% stretch to about 35%stretch, or at about 35% stretch. According to various embodiments, thefabric having the stretch capacity may be positioned along one or moresides that span the depth of the mattress. According to variousembodiments, the fabric having the stretch capacity may additionally, oralternatively, be positioned along a bottom surface of the mattress 200.Further, the one or more polymer may be formed of isocyanate and polyol.In some embodiments, the one or more polymer may includepolyisocyanurate and/or polyurethane. In various embodiments, the one ormore polymer (or portions thereof) may additionally, or alternatively,include an elastomer such as latex.

As shown in FIG. 2 , at least one of the one or more polymer of themattress 200 includes a first plurality of voids 214 that traverse atleast a portion of the width W1 of the mattress 200. Further, the firstplurality of voids 214 are located about or in the lower surface 203 ofthe polymer of the mattress 200, where the lower surface 203 is oppositethe upper surface 201 of the polymer or the mattress 200. The polymerspans a depth D1 that extends from the upper surface 201 to the lowersurface 203. Various embodiments of the polymer may include one or morelayers such as a first layer 234 proximate the upper surface 201 and asecond layer 230 proximate the lower surface 203. Further, a third layer232 may be located between the first layer 234 and the second layer 230.According to various embodiments, at least one layer of the multiplelayers may include a different density than at least one other layer ofthe multiple layers. For instance, the first layer 234 may be less denseand softer than the second layer 230 and/or third layer 232. Alsoaccording to various embodiments, one or more of the layers of themultiple layers may include an additive such as, for example, a phasechange material, calcium carbonate, silica, fly ash, barium sulfate,hydrocarbon gels, magnetic or magnetizable materials, foam digesters,etc. The one or more layers may also comprise different materialcompositions. For example, the first layer 234 may include a polymericfoam, and the second layer 230 and/or third layer 232 may include anelastomer. Various other modifications and configurations are alsocontemplated herein.

The first plurality of voids 214 are defined by polymer walls such aswalls 290, 292 depicted in FIG. 2 that define void 218. The voids 214allow for separation of the walls when the mattress 200 is folded orbent, which is why the void 218 depicted near the axis point or thepoint of the mattress 200 corresponding to the location 252 where thebase 250 inclines appears wider than the other voids 214. The firstplurality of voids 214 depicted in FIG. 2 are substantially congruentand traverse the width W1 of the mattress 200. However, when themattress 200 is not bent and the base 250 is flat, the void 218 is thesame width as the other voids 214. In various embodiments, the firstplurality of voids 214 form a crease separating a first wall (e.g. wall290) from a second wall (e.g. wall 292) where the one or more walls thatdefine the first plurality of voids 214 further define polymer feet andthe first wall forms a first foot that is separate from a second footdefined by the second wall. Specifically, each polymer foot of thepolymer feet is defined by one or more walls of the polymer walls.Further, the crease may extend in the depth direction away from thelower surface 203 towards the upper surface 201 and stop at acylindrical internal pocket 216 that is devoid of polymer and may beproximal to the upper surface 201.

The thickness of the voids 214 and the number of voids 214 directlyinfluence the size of the polymer feet and the number of polymer feet.During formation of the mattress 200, the polymer may initially bedevoid of any voids 214. After the polymer is cut or molded to thedesired length L1 and width W1, portions of the polymer may be cut outand removed from the mattress 200 to form the voids 214. For example, iffive voids are formed in the lower surface 203 of the polymer, then thewalls defining the voids would further define six feet along the lowersurface 203 of the polymer. According to various embodiments, multiplevoids of the first plurality of voids 214 may be regularly spaced at setintervals. In other embodiments, the voids 214 may be placed atirregular intervals. According to various embodiments, at least some ofthe first plurality of voids 214 may be congruent and/or parallel, andaccording to one embodiment, all of the voids 214 may be congruentand/or parallel. The size of the voids 214 may also determine of thepolymer feet. For instance, if the voids 214 are relatively thick, thenthe size and thickness of the polymer feet may be smaller. According tovarious embodiments, the voids 214 may be parallel channels thattraverse the width of the mattress, and the thickness of the parallelchannels may be within a range of about 0.1 inch to about 6 inches, arange of about 1 inch to about 5 inches, a range of about 2 inches toabout 4 inches, or more specifically about 4 inches thick.

Additionally, the first plurality of voids 214 may have various heights.According to one embodiment, one void of the first plurality of voids214 may be taller than one or more other voids of the first plurality ofvoids 214. In other embodiments, the first plurality of voids 214 may bethe same height or there may be one or more voids having a first heightand one or more other voids having a second height. Further, in someembodiments, one or more additional voids may have a third height. Theheight of the first plurality of voids 214 may extend in a depthdirection that corresponds to the depth D1 of the mattress 200. Forexample, the one or more of the voids 214 may extend away from the lowersurface 203 and towards the upper surface 201 a height of at least oneinch. In various embodiments, each of the voids 214 may have a height ofat least one inch. Further, one or more of the voids of the firstplurality of voids 214 may extend in a depth direction corresponding tothe depth D1 a distance/height within a range of about 1 inch to about 5inches, or more particular a distance of about 5 inches. For instance,the total depth D1 of the polymer of the mattress 200 may be 10 totalinches, with the 4 inches most proximate to the upper surface 201 havingone or more layers and the lowermost 6 inches of the polymer including abase material (e.g. polymeric foam, an elastomer, etc.) into which thefirst plurality of voids 214 are cut. One or more of the first pluralityof voids 214 may extend the entire height of the 6-inch base, or mayonly extend a height of 5 inches extending from the lower surface 203towards the upper surface 201.

Advantageously, the larger (i.e. thicker and taller) the voids 214 andthe more polymer that is removed, the more compactly the mattress 200can fold or roll during packing so that the mattress 200 can betransported and shipped less expensively. Additionally, by packing themattress into a smaller box or packaging, shipping and transportationcosts are reduced, the mattress takes up less space on the shelves instores, and it is easier for consumers or delivery companies totransport the mattress to homes. In some embodiments, the firstplurality of voids 214 may remove at least 5% volume of the polymer thatdefines the length and width of the mattress 200. In particular, thefirst plurality of voids 214 may remove between 5% volume and 60% volumeof the polymer that defines the length and width of the mattress,between 10% volume and 30% volume of the polymer defined by the lengthand width of the mattress, between 15% volume and 20% volume of thepolymer defined by the length and the width of the mattress, or about19% volume of the polymer defined by the length and the width of themattress. Additionally, the first plurality of voids 214 may enable acleaner fold 240 when the mattress 200 is inclined. By having a singlefold 240 that bends inward rather than forming ridges that protrude fromthe upper surface 201 of the mattress 200, the mattress 200 may be morecomfortable when positioned in an inclined position.

Further, the mattress 200 may include a plurality of regions, where eachregion is defined by the polymer feet and the plurality of regionscorrespond to a plurality of lower surface regions. For instance, afirst region 202 may include a first lower surface region of the polymerthat includes multiple polymer feet with at least one foot 210 of themultiple polymer feet that has a first size that is different fromanother polymer foot 212 of a lower surface region that corresponds to asecond region 204 of the mattress 200. In particular, the other foot 212of the polymer feet has a size that spans a greater distance along thelength L1 of the mattress 200 than the at least one foot 210 that hasthe first size. Specifically, the other foot 212 is thicker than the atleast one foot 210. According to various embodiments, the first region202 may include multiple voids, and the multiple voids may be paralleland/or congruent. In various embodiments, the second region 204 mayinclude multiple voids defining the feet such that the second region 204has one or more feet 212 that are larger in size than the feet 210 ofthe first region 202. According to various embodiments, the mattress 200may also include a third region 206 that includes at least two feet ofthe polymer feet 210. In one embodiment the at least two feet of thethird region 206 may mirror, in size and in shape, multiple feet of thefirst region 202 such that a foot of first region 202 is the same sizeas a foot of the third region 206. In various embodiments, one or morefeet 212 of the second region 204 may be larger than one or more feet210 of the third region 206. In particular, at least one foot of the atleast two feet of the third region 206 may have a size that is smallerand spans less of a distance along the length of the mattress 200 thanat least one foot of the second region 204.

Further, according to various embodiments at least one polymer foot ofthe polymer feet extends the width of the mattress, multiple feet of thepolymer feet extend the width of the mattress, or each foot of thepolymer feet extends the width of the mattress.

FIGS. 3A-3C depict a mattress 300 that may comprise and/or may besimilar to the mattress 200 described above with reference to FIG. 2 ,and the description contained herein directed thereto equally applies tomattress 300 but may not be repeated herein for brevity sake. Like orsimilar components and aspects of mattress 200 to mattress 300 of FIGS.3A-3C are thereby indicated by like reference numerals preceded with“3”. Mattress 300 is depicted with the first region 302 being inclinedand the third region 306 being raised but to a lesser extent than thefirst region 302. The first region 302 is inclined at a larger anglethan the third region 306, and the two inclines still provide cleanfolds 340 near the midpoint of the mattress 300. As described above, theclean folds prevent ridges from protruding from the upper surface 301 ofthe mattress 300. The manner in which the base 350 is inclined with thelarger angle for the first region 302 resulted in one void 318 wideningdue to the compressive forces applied to the polymer. In contrast, themanner in which the base 350 is inclined in the area about the thirdregion 306 causes a void 320 to narrow such that one of the feet 310 ofthe third region 306 contacts one of the feet 312 of the second region304.

Further, as depicted in FIGS. 3B and 3C, in addition to a plurality ofvoids 314 that at least partially traverse the width W1 of the mattress300, the mattress 300 also includes at least one groove 360 about or inthe lower surface 303, where the at least one groove 360 extends thelength L1 of the mattress 300. According to various embodiments, the atleast one groove 360 includes multiple grooves. Further, according tovarious embodiments, a groove of the at least one groove 360 may have aheight that extends in a depth direction corresponding to the depth D1extending away from the lower surface 303 that is a height/distance ofat least one inch. More particularly, according to various embodiments,one or more grooves of the at least one groove 360 may extend in thedepth direction a height/distance within a range of about 1 inch toabout 5 inches, or a height/distance of 5 inches. As described abovewith respect to mattress 200, if the mattress 300 has a depth D1 of 10inches with the base layer being 6 inches, the at least one groove 360may extend the full height of the base layer or traverse the lower 5inches of the base layer. According to various embodiments where the atleast one groove 360 includes multiple grooves, the multiple grooves maybe the same height/distance, or one or more of the grooves have a firstheight and one or more other grooves have a second height. Further,multiple grooves of the at least one groove 360 may have a height of atleast one inch, a height within a range of about 1 inch to about 5inches, or have a height of about 5 inches. In some embodiments, eachgroove of the multiple grooves may have a height of at least one inch, aheight within a range of about 1 inch to about 5 inches, or have aheight of about 5 inches. As depicted in FIG. 3C, the at least onegroove 360 may include one or more first grooves 362 having a firstheight and one or more other grooves 364 having a second height.Additionally, although not shown, one or more additional grooves mayinclude a third height.

Additionally, the at least one groove 360 may include a thickness withina range of about 0.1 inch to about 6 inches, within a range of about 1inch to about 5 inches, within a range of about 2 inches to about 4inches, or be about 4 inches. Advantageously, by removing volume fromthe polymer by the at least one groove 360, the mattress 300 may furtherbe more tightly packed or compressed into a box or package fortransportation and shipment. According to one embodiment, the at leastone groove 360 may remove an additional volume beyond the volume alreadyremoved by the plurality of voids 314. According to various embodiments,based on the thickness, height, and number of grooves, the at least onegroove 360 may remove between 1% volume and 60% volume of the polymerdefined by the length L1 and width W1 of the mattress 300, may removebetween 5% and 30% volume, may remove between 10% and 20% volume, or mayremove 19% volume.

Referring now to FIGS. 4A-4E, various embodiments of lower surfaces 403of a mattress 400 are depicted. Mattress 400 may comprise and/or may besimilar to the mattress 200 and/or mattress 300 described above withreference to FIGS. 2-3C, and the description contained herein directedthereto equally applies to mattress 400 but may not be repeated hereinfor brevity sake. Like or similar components and aspects of mattress 200and mattress 300, to mattress 400 of FIGS. 4A-4E are thereby indicatedby like reference numerals preceded with “4”. The mattress 400 includesa first region 402, a second region 404, and various embodiments mayfurther include a third region 406. The first region 402 and thirdregion 406 include smaller feet 410 than the larger feet 412 of thesecond region 404. The mattress 400 also includes a plurality of voids414, where the number, thickness, and shape of the voids determine thenumber, shape, and size of the feet. As depicted in FIGS. 4B-4E, themattress 400 may further includes at least one groove 460 that extendsthe length L1 of the mattress 400. The number, thickness, and shape ofthe at least one groove 460 may impact the amount of polymer that isremoved, which can allow for the mattress 400 to be folded andcompressed to a greater extent for packaging and shipment.

FIGS. 5A-5D depict side views of a mattress 500 with a plurality ofvoids 514 along the length of the mattress 500. Mattress 500 maycomprise and/or may be similar to mattresses 200, 300 and/or 400described above with reference to FIGS. 2-4E, and the descriptioncontained herein directed thereto equally applies to mattress 500 butmay not be repeated herein for brevity sake. Like or similar componentsand aspects of mattresses 200, 300, 400, to mattress 500 of FIGS. 5A-5Dare thereby indicated by like reference numerals preceded with “5”.Mattress 500 includes a first region 502, a second region 504 and athird region 506 with the first region 502 and the third region 506having feet 510 of a first size that are smaller than the feet 512 ofthe second region. The feet 510 of the first region 502 and/or thirdregion 506 may not be identical and may have various thicknesses,depths, shapes, etc. either within each respective region (i.e., withinfirst region 502 or within third region 506) or when comparing feet 510of the first region 502 to feet 510 of the third region 506. Similarlythe feet 512 of the second region 504 may have varying sizes, shapes,depths, etc., but all feet 512 of the second region 504 would span agreater distance along the length L1 of the mattress 500 (i.e., would bethicker) than any of the feet 510 of the first region 502 and/or thirdregion 506. For example, referring to FIG. 5A, foot 524 is smaller inthickness than foot 522, which is also smaller in thickness than foot526. However, feet 524, 522, and 526 are all larger than feet 510.Advantageously, by having thicker feet 512 in the second region 504,more support is provided to a user of the mattress 500 at the heaviestareas of the user (e.g., the hips, midsection, and/or shoulders). Thevoids 514 can be more frequent, thicker, deeper, larger, etc. in thefirst region 502 and the third region 506 because there is less weightapplied by the user to these regions of the mattress 500. Further,according to various embodiments, the voids 514 may not traverse certainlayers, such as layers 532 or 534 of the mattress 500 in order toprovide a smooth resting surface upon which the user rests.

As depicted in FIG. 5B, the shape of foot 525 of feet 512 is slightlydifferent than foot 523 of feet 512, even though both are larger thanfeet 510. The different shapes may allow for different amounts ofsupport to the user at the user's pressure points in order to providemaximum support. Referring now to FIG. 5C, as depicted, the voids 514may include rectangular channels 527, and the rectangular channels mayhave varying thickness, which may determine the size of the feet. Forinstance, the mattress 500 may include rectangular channels 527 of alarger thickness 515 to form the smaller feet 510, and the mattress 500may include rectangular channels 527 of a smaller thickness 517 to formthe larger feet 512. Referring now to FIG. 5D, the voids 514 may includecircular channels 519, which advantageously may allow the smaller feet510 and/or the larger feet 512 to have more surface area in contact withthe base situated below the mattress 500.

Referring now to FIGS. 6A-6B, a side view of a mattress 600 is depictedthat has multiple grooves 660 situated along the width W1 of themattress 600. Mattress 600 may comprise and/or may be similar tomattresses 200, 300, 400 and/or 500 described above with reference toFIGS. 2-5D, and the description contained herein directed theretoequally applies to mattress 600 but may not be repeated herein forbrevity sake. Like or similar components and aspects of mattresses 200,300, 400, 500 to mattress 600 of FIGS. 6A-6C are thereby indicated bylike reference numerals preceded with “6”. The mattress 600 may includemultiple layers 630, 632, 634, according to various embodiments, withthe grooves 660 being cut into the base layer 630. The grooves 660 mayinclude various heights such as height 662 or height 664. The differentheights may be determined based on the amount of folding or rolling thatmay occur during packing at the various locations. For example, if themattress 600 needs only a partial fold at a particular location, then asmaller height such as height 662 may be preferred for that particularlocation, whereas if a full fold is needed for packing then a largerheight such as height 664 may be preferred. Further, the mattress 600may include a single groove or a plurality of grooves, and the groovesmay have varying thicknesses.

According to various embodiments of mattresses 200, 300, 400, 500,and/or 600 described above, any one of the aforementioned mattresses mayfurther include one or more polymers having one or more perforations.For example, the one or more perforations may at least partiallytraverse the depth of the one or more polymers, or more particularly mayextend the full depth of the one or more polymers. Further, the one ormore perforations may include a diameter within a range of about 0.25inches to about 3 inches, a range of about 0.5 inches to about 2 inches,a range of about 0.75 inches to about 1.5 inches, or more particularly adiameter of about 1 inch. The one or more perforations may remove atleast 1% of a total volume of the one or more polymers. For instance,the one or more perforations may remove a total volume of the one ormore polymers that is within a range of about 1% to about 20%, a rangeof about 5% to about 15%, a range of about 8% to about 12%, or about 10%total volume of the one or more polymers.

In some embodiments, the mattresses, cushions, and body-support pads ormats disclosed herein may comprise dual-sided voids, gaps and/orgrooves. That is, a respective mattress, cushion, or body-support pad ormat may comprise a first plurality of voids, gaps and/or grooves locatedabout or in the lower surface of the polymer of the respective mattress,cushion, or body-support pad or mat, and a second plurality of voids,gaps and/or grooves located about or in the upper surface of the polymerof the respective mattress, cushion, or body-support pad or mat.

In one embodiment, the second plurality of voids, gaps, and/or groovesmay differ from the first plurality of voids, gaps, and/or grooves interms of at least one of dimension, configuration, and quantity of thevoids, gaps and/or grooves, such as shape, thickness, height, number,and layout or arrangement of the voids, gaps and/or grooves. Forexample, the first plurality of voids, gaps and/or grooves located aboutor in the lower surface of the polymer of the respective mattress,cushion, or body-support pad or mat can be any one of the voids andgrooves or combinations thereof described above in FIGS. 2-6C; and thesecond plurality of voids, gaps and/or grooves located about or in theupper surface of the polymer of the respective mattress, cushion, orbody-support pad or mat can be any other one of the voids and grooves orcombinations thereof described above in FIGS. 2-6C.

In another embodiment, the second plurality of voids, gaps, and/orgrooves may be the same as the first plurality of voids, gaps, and/orgrooves in terms of at least one of dimension, configuration, andquantity of the voids, gaps and/or grooves, such as shape, thickness,height, number, and layout or arrangement of the voids, gaps and/orgrooves. For example, the first plurality of voids, gaps and/or grooveslocated about or in the lower surface of the polymer of the respectivemattress, cushion, or body-support pad or mat, and the second pluralityof voids, gaps and/or grooves located about or in the upper surface ofthe polymer of the respective mattress, cushion, or body-support pad ormat, can both be any same one of the voids and grooves or combinationsthereof described above in FIGS. 2-6C. For instance, the secondplurality of voids and/or grooves may mirror the first plurality ofvoids and/or grooves with respect to a middle surface of the polymer ofthe respective mattress, cushion, or body-support pad or mat. The middlesurface is located between and parallel to the upper surface and thelower surface of the polymer of the respective mattress, cushion, orbody-support pad or mat.

In some embodiments, the second plurality of voids, gaps, and/or groovesmay be arranged in the upper surface to offset the first plurality ofvoids, gaps, and/or grooves in the direction of the length and/or widthof the respective mattress, cushion, or body-support pad or mat, suchthat the middle, center or symmetry line of at least one of the secondplurality of voids, gaps, and/or grooves does not overlap with themiddle, center or symmetry line of corresponding one of the firstplurality of voids, gaps, and/or grooves. The middle, center or symmetryline is a vertical line in the direction of depth of the respectivemattress, cushion, or body-support pad or mat. Such offset can provide abalanced pressure distribution on the polymer of the respectivemattress, cushion, or body-support pad or mat when a user sits or lieson the respective mattress, cushion, or body-support pad or mat, whichcan provide desired load support and comfort while allowing for reducingthe volume and/or weight of the respective mattress, cushion, orbody-support pad or mat for decreasing shipping cost, in addition toprevention of the bunching and ridges caused by folding or bendingwithout causing the respective mattress, cushion, or body-support pad ormat.

As disclosed herein, the description of the first plurality of voids,gaps and/or grooves located about or in the lower surface of the polymerof the respective mattress, cushion, or body-support pad or mat asdescribed above with reference to FIGS. 2-6C equally applies to thesecond plurality of voids, gaps and/or grooves located about or in theupper surface of the polymer of the respective mattress, cushion, orbody-support pad or mat. Therefore, detailed description of the secondplurality of voids, gaps and/or grooves may not be repeated herein forbrevity sake.

Specifically, in addition to the first plurality of voids, gaps and/orgrooves located about or in the lower surface of the polymer of therespective mattress, cushion, or body-support pad or mat as disclosedabove in FIGS. 2-6C, the respective mattress, cushion, or body-supportpad or mat may further comprise a second plurality of voids, gaps and/orgrooves located about or in the upper surface of the at least onepolymer of the one or more polymers of the respective mattress, cushion,or body-support pad or mat. The second plurality of voids and/or groovesmay traverse at least a second portion of the width and/or length of therespective mattress, cushion, or body-support pad or mat. The secondplurality of voids and/or grooves are also defined by the correspondingpolymer walls located about or in the upper surface of the at least onepolymer of the one or more polymers of the respective mattress, cushion,or body-support pad or mat.

Accordingly, the second plurality of voids and/or grooves define asecond plurality of polymer feet, wherein each polymer foot of thesecond plurality of polymer feet is defined by one or more walls of thecorresponding polymer walls located about or in the upper surface.

Similarly, the respective mattress, cushion, or body-support pad or matmay further comprise a plurality of upper surface regions, wherein afirst region of the plurality of upper surface regions includes at leastone foot of the second plurality of polymer feet that has a third size,and wherein a second region of the plurality of upper surface regionsincludes at least one other foot of the second plurality of polymer feetthat has a fourth size. The at least one other foot having the fourthsize spans a greater distance along the length of the respectivemattress, cushion, or body-support pad or mat than the at least one foothaving the third size.

Accordingly, in some embodiments, a mattress, cushion, or body-supportpad or mat disclosed herein may comprise: one or more polymers at leastpartially defining a length and a width of the respective mattress,cushion, or body-support pad or mat, wherein the one or more polymersspan a depth that is perpendicular to the length and the width of therespective mattress, cushion, or body-support pad or mat, and thatextend from an upper surface of at least one polymer of the one or morepolymers that is proximate to where a user rests to a lower surface ofthe at least one polymer of the one or more polymers, and wherein thelower surface is opposite the upper surface that is proximate to wherethe user rests; a first plurality of voids in the at least one polymerof the one or more polymers, the first plurality of voids traversing atleast a first portion of the width of the mattress, wherein the firstplurality of voids are located about the lower surface, and wherein thefirst plurality of voids are defined by polymer walls of the at leastone polymer of the one or more polymers; a first plurality of polymerfeet, wherein each polymer foot of the first plurality of polymer feetis defined by one or more walls of the polymer walls; a plurality oflower surface regions, wherein a first region of the plurality of lowersurface regions includes at least one foot of the first plurality ofpolymer feet that has a first size, and wherein a second region of theplurality of lower surface regions includes at least one other foot ofthe first plurality of polymer feet that has a second size; a secondplurality of voids in the at least one polymer of the one or morepolymers, the second plurality of voids traversing at least a secondportion of the width of the respective mattress, cushion, orbody-support pad or mat, wherein the second plurality of voids arelocated about the upper surface, and wherein the second plurality ofvoids are defined by the polymer walls of the at least one polymer ofthe one or more polymers; a second plurality of polymer feet, whereineach polymer foot of the second plurality of polymer feet is defined byone or more walls of the polymer walls; and a plurality of upper surfaceregions, wherein a first region of the plurality of upper surfaceregions includes at least one foot of the second plurality of polymerfeet that has a third size, and wherein a second region of the pluralityof upper surface regions includes at least one other foot of the secondplurality of polymer feet that has a fourth size. The at least one otherfoot having the second size spans a greater distance along the length ofthe respective mattress, cushion, or body-support pad or mat than the atleast one foot having the first size; and the at least one other foothaving the fourth size spans a greater distance along the length of therespective mattress, cushion, or body-support pad or mat than the atleast one foot having the third size.

The second plurality of voids may mirror the first plurality of voidswith respect to a middle surface of the at least one polymer, the middlesurface located between and parallel to the upper surface and the lowersurface of the at least one polymer. The second plurality of voids maydiffer from the first plurality of voids in terms of at least one ofdimension, configuration, and quantity. The one or more polymers of therespective mattress, cushion, or body-support pad or mat may furthercomprise at least one groove in the upper surface of the at least onepolymer that extends the length of the respective mattress, cushion, orbody-support pad or mat. The at least one groove in the upper surface ofthe at least one polymer may mirror the at least one groove in the lowersurface of the at least one polymer with respect to the middle surfaceof the at least one polymer. The at least one groove in the uppersurface of the at least one polymer may differ from the at least onegroove in the lower surface of the at least one polymer in terms of atleast one of dimension, configuration, and quantity.

FIG. 7 depicts a side views of an example mattress (cushion, orbody-support pad or mat) 700 having dual-sided voids, gaps and/orgrooves in various embodiments. The mattress 700 may comprise a firstplurality of voids 714 and a second plurality of void 724 along thelength of the mattress 700. Mattress 700 may comprise and/or may besimilar to mattresses 200, 300, 400, 500 and/or 600 described above withreference to FIGS. 2-6C, and the description contained herein directedthereto equally applies to mattress 700 but may not be repeated hereinfor brevity sake. Like or similar components and aspects of mattresses200, 300, 400, 500, 600, to mattress 700 of FIG. 7 are thereby indicatedby like reference numerals preceded with “7”.

The mattress 700 may include a plurality of lower surface regionsincluding, for example, a first lower surface region 702 and a secondlower surface region 704 having feet 710. The feet 710 of the firstlower surface region 702 and/or second lower surface region 704 may notbe identical and may have various thicknesses, depths, shapes, etc.either within each respective region (i.e., within the first lowersurface region 702 or within the lower surface second region 704) orwhen comparing feet 710 of the first lower surface region 702 to feet710 of the second lower surface region 704. For example, the foot 710 aof the second lower surface region 704 may span a greater distance alongthe length L1 of the mattress 700 (i.e., would be thicker) than the foot710 b of the first lower surface region 702.

The mattress 700 may include a plurality of upper surface regionsincluding, for example, a first upper surface region 732 and a secondupper surface region 734 having feet 720. The feet 720 of the firstupper surface region 732 and/or second upper surface region 734 may notbe identical and may have various thicknesses, depths, shapes, etc.either within each respective region (i.e., within the first uppersurface region 732 or within the upper surface second region 734) orwhen comparing feet 720 of the first upper surface region 732 to feet720 of the second upper surface region 734. For example, the foot 720 aof the first upper surface region 732 may span a greater distance alongthe length L1 of the mattress 700 (i.e., would be thicker) than the foot720 b of the first upper surface region 732. As another example, thefoot 720 c is shaped differently than other feet 720.

The second plurality of voids 724 are, as depicted, different from thefirst plurality of voids 714. The second plurality of voids 724including widthwise channels of a parallelogram cross-section arearranged at an angle with respect to the upper surface of the polymer sothat displacement is minimal to provide maximum support but weight andpacking size of the mattress 700 could be decreased when a user rests onthe mattress 700.

In various embodiments, the second plurality of voids may comprise voidsof any suitable configurations. For example, FIG. 8 depict a side viewof an example mattress (cushion, or body-support pad or mat) 800 havingdual-sided voids, gaps and/or grooves. The mattress 800 may comprise afirst plurality of voids 814 and a second plurality of void 824 alongthe length of the mattress 800. Mattress 800 may comprise and/or may besimilar to mattresses 200, 300, 400, 500, 600 and/or 700 described abovewith reference to FIGS. 2-67 , and the description contained hereindirected thereto equally applies to mattress 800 but may not be repeatedherein for brevity sake. Like or similar components and aspects ofmattresses 200, 300, 400, 500, 600, 700, to mattress 800 of FIG. 8 arethereby indicated by like reference numerals preceded with “8”.

The mattress 800 may include a plurality of lower surface regionsincluding, for example, a first lower surface region 802 and a secondlower surface region 804 having feet 810. The feet 810 of the firstlower surface region 802 and/or second lower surface region 804 may notbe identical and may have various thicknesses, depths, shapes, etc.either within each respective region (i.e., within the first lowersurface region 802 or within the lower surface second region 804) orwhen comparing feet 810 of the first lower surface region 802 to feet810 of the second lower surface region 804.

The mattress 800 may include an upper surface region 832 having feet820. The second plurality of voids 824 are, as depicted, different fromthe first plurality of voids 814. The second plurality of voids 824including widthwise channels of a zigzag cross-section are arranged inthe upper surface of the polymer so that displacement is minimal toprovide maximum support but weight and packing size of the mattress 800could be decreased when a user rests on the mattress 800.

In some embodiments, at least one of the first and/or second pluralityof voids may be partially filled with at least one material having adensity lower than and a stretchability greater than a density and astretchability of the polymer of the one or more polymers, respectively.The at least one material may include, but not limited to, anotherpolymer, a foam, a latex, and/or any other suitable material. Forexample, the at least one material may fill the at least one of theplurality of voids partially in the height of the at least one void, inthe thickness of the at least one void, and/or in the width of themattress.

In some embodiments, at least one of the first and/or second pluralityof voids may be fully filled with the at least one material. Forexample, the at least one material may fill the at least one of theplurality of voids fully in the height of the at least one void, in thethickness of the at least one void, and/or in the width of the mattress.

In some embodiments, the at least one groove in the upper surface and/orthe lower surface of the polymer may be partially filled with the atleast one material. For example, the at least one material may fill theat least one groove partially in the height of the at least one groove,in the thickness of the at least one groove, and/or in the length of themattress.

In some embodiments, the at least one groove in the upper surface and/orthe lower surface of the polymer may be fully filled with the at leastone material. For example, the at least one material may fill the atleast one groove fully in the height of the at least one groove, in thethickness of the at least one groove, and/or in the length of themattress.

In some embodiments, at least one of the first and/or second pluralityof voids may be partially filled with at least one gas pocket. The atleast one gas pocket may be configured to have at least one gas releasevalve and at least one gas filling valve, and the at least one gaspocket may be filled with a gas selected from the group consisting ofair, nitrogen, argon, and/or any other suitable gas. For example, the atleast one gas pocket may fill the at least one of the plurality of voidspartially in the height of the at least one void, in the thickness ofthe at least one void, and/or in the width of the mattress.

In some embodiments, at least one of the first and/or second pluralityof voids may be fully filled with the at least one gas pocket. Forexample, the at least one gas pocket may fill the at least one of theplurality of voids fully in the height of the at least one void, in thethickness of the at least one void, and/or in the width of the mattress.

In some embodiments, the at least one groove in the upper surface and/orthe lower surface of the polymer may be partially filled with the atleast one gas pocket. For example, the at least one gas pocket may fillthe at least one groove partially in the height of the at least onegroove, in the thickness of the at least one groove, and/or in thelength of the mattress.

In some embodiments, the at least one groove in the upper surface and/orthe lower surface of the polymer may be fully filled with the at leastone gas pocket. For example, the at least one gas pocket may fill the atleast one groove fully in the height of the at least one groove, in thethickness of the at least one groove, and/or in the length of themattress.

In some embodiments, the first and/or second plurality of voids may beformed by layering a plurality of sub-layer polymers of the polymer ofthe one or more polymers, along the width or the length or both thewidth and the length.

In some embodiments, the at least one groove in the upper surface and/orthe lower surface of the polymer may be formed by layering a pluralityof sub-layer polymers of the one or more polymers, along the width orthe length or both the width and the length.

In some embodiments, the mattresses, cushions, or body-support pads ormats disclosed herein may include at least one non-skid bottom materialcoupled to the lower surface of the one or more polymers. In someembodiments, the at least one non-skid bottom material may be coupled toa bottom surface of the mattress cover that is in adjacent to the lowersurface of the one or more polymers. The bottom surface of the mattresscover or the lower surface of the one or more polymers may be in contactwith a top surface of the adjustable bed frame, such that the at leastone non-skid bottom material can prevent the mattress from unnecessarysliding with respect to the top surface of the adjustable bed frame.

In some embodiments, the at least one non-skid material may include, butnot limited to, selectively placed grips/adhesives, a full sheet ofnon-skid material, hook-and-loop fasteners, buttons, zippers, creases,or any other suitable materials/patterns/mechanisms that would increasethe coefficient of friction between the mattress and the adjustable bedframe. For example, the at least one non-skid materials may be slipresistant fabric that offers grip in wet, dry, hot and cold conditions.The slip resistant fabric may include Polyvinyl chloride (PVC).

In some embodiments, the lower surface of the one or more polymers maybe configured to have perforations that might facilitate stretch if thenon-skid material is not very flexible and stretchable. In someembodiments, the non-skid material may be a laminate positioned alongthe bottom of each individual polymer foot. Portions of the polymer feetmay be exposed and the mattress cover attaches or hooks to the sidewallsof the polymer feet so that the polymer feet provide the coefficient offriction that would be missing with a standard mattress cover.

The descriptions provided above for mattresses 200, 300, 400, 500, 600,700, and/or 800 are equally applicable to any cushion and/orbody-support pad or mat.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprise” (andany form of comprise, such as “comprises” and “comprising”), “have” (andany form of have, such as “has” and “having”), “include” (and any formof include, such as “includes” and “including”), “contain” (and any formcontain, such as “contains” and “containing”), and any other grammaticalvariant thereof, are open-ended linking verbs. As a result, a method orarticle that “comprises”, “has”, “includes” or “contains” one or moresteps or elements possesses those one or more steps or elements, but isnot limited to possessing only those one or more steps or elements.Likewise, a step of a method or an element of an article that“comprises”, “has”, “includes” or “contains” one or more featurespossesses those one or more features, but is not limited to possessingonly those one or more features.

As used herein, the terms “comprising,” “has,” “including,”“containing,” and other grammatical variants thereof encompass the terms“consisting of” and “consisting essentially of.”

The phrase “consisting essentially of” or grammatical variants thereofwhen used herein are to be taken as specifying the stated features,integers, steps or components but do not preclude the addition of one ormore additional features, integers, steps, components or groups thereofbut only if the additional features, integers, steps, components orgroups thereof do not materially alter the basic and novelcharacteristics of the claimed compositions or methods.

All publications cited in this specification are herein incorporated byreference as if each individual publication were specifically andindividually indicated to be incorporated by reference herein as thoughfully set forth.

Subject matter incorporated by reference is not considered to be analternative to any claim limitations, unless otherwise explicitlyindicated.

Where one or more ranges are referred to throughout this specification,each range is intended to be a shorthand format for presentinginformation, where the range is understood to encompass each discretepoint within the range as if the same were fully set forth herein.

While several aspects and embodiments of the present invention have beendescribed and depicted herein, alternative aspects and embodiments maybe affected by those skilled in the art to accomplish the sameobjectives. Accordingly, this disclosure and the appended claims areintended to cover all such further and alternative aspects andembodiments as fall within the true spirit and scope of the invention.

What is claimed is:
 1. A body support cushion, comprising: one or morepolymer layers at least partially defining a length and a width of thecushion, wherein the one or more polymers span a depth that isperpendicular to the length and the width of the cushion and extend froman upper surface of the one or more polymer layers that is proximate towhere a user rests to a lower surface of the one or more polymer layersthat is opposite the upper surface; a plurality of voids in at least onepolymer layer of the one or more polymer layers, the plurality of voidsfully traversing the width of the cushion, wherein the plurality ofvoids extend from the lower surface and form polymer walls of the atleast one polymer layer; a plurality of polymer feet formed by the atleast one polymer layer via the plurality of voids, wherein each polymerfoot is defined by adjacent polymer walls; and a plurality of lowersurface regions formed of the plurality of voids and the plurality ofpolymer feet, the plurality of lower surface regions comprising a firstregion that includes a plurality of first feet of a first size, and asecond region that includes a plurality of second feet of a second size,wherein each second foot of the second size spans a greater distancealong the length of the cushion than each first foot of the first size.2. The cushion of claim 1, wherein the first and second regions areadjacent to each other along the length of the cushion.
 3. The cushionof claim 2, wherein the plurality of lower surface regions furthercomprises a third region that includes at least one third foot of athird size that spans a distance along the length of the cushion thatdiffers from at least one of the first and second sizes.
 4. The cushionof claim 3, wherein each third foot of the third size spans a smallersize along the length of the cushion than each second foot of the secondsize.
 5. The cushion of claim 4, wherein the third size is substantiallythe same as the first size.
 6. The cushion of claim 4, wherein thesecond region is arranged between and adjacent to the first and thirdregions along the length of the cushion.
 7. The cushion of claim 6,wherein the first region is positioned at a first end of the cushionalong the length direction, the third the is positioned at a second endof the cushion along the length direction, and the second region extendsbetween the first and second regions along the length direction.
 8. Thecushion of claim 1, wherein the plurality of voids extend parallel toeach other.
 9. The cushion of claim 1, wherein the plurality of voidsremove between 10% volume and 30% volume of the one or more polymerlayers defined by the length and the width of the cushion.
 10. Thecushion of claim 1, wherein each of the plurality of voids extend in adepth direction corresponding to the depth of at least one inch from thelower surface towards the upper surface.
 11. The cushion according toclaim 10, where at least one void of the first plurality of voidsextends in a depth direction corresponding to the depth a first distancefrom the lower surface towards the upper surface and at least one othervoid of the first plurality of voids extends in the depth direction asecond distance from the lower surface towards the upper surface,wherein a third void of the first plurality of voids extends in thedepth direction a third distance from the lower surface towards theupper surface, wherein the third distance is longer than both the firstdistance and the second distance
 12. The cushion of claim 1, wherein theone or more polymer layers comprise one or more of a polyurethane layer,a polyisocyanurate layer and a polyol layer.
 13. The cushion of claim 1,wherein the one or more polymer layers include a first polymer layerproximate the upper surface, and a second polymer layer proximate thelower surface that differs from the first polymer layer, wherein theplurality of voids extend into the second polymer layer and not thefirst polymer layer, and wherein the plurality of polymer feet areformed of the second polymer layer.
 14. The cushion of claim 13, whereinthe first polymer layer and the second polymer layer comprise differentdensities and are formed of differing polymer materials.
 15. The cushionof claim 1, wherein the cushion further comprises at a plurality groovesin at least one polymer layer of the one or more polymer layers, theplurality of grooves extending along the length of the cushion, andwherein the plurality of grooves extend from the lower surface andintersect at least one of the plurality of voids.
 16. The cushion ofclaim 15, wherein each of the plurality of grooves extend in the depthdirection from the lower surface within a range of about 1 inch to about5 inches, and wherein the plurality of grooves are substantially evenlyspaced apart in the width direction.
 17. The cushion of claim 1, whereinthe one or more polymer layers further comprise a plurality ofperforations that at least partially traverse the depth of the one ormore polymer layers, wherein each of the plurality of perforationscomprise a diameter within a range of about 0.25 inches to about 3inches, and remove a total volume of the one or more polymers within arange of about 5% to about 15%.
 18. The cushion of claim 1, wherein atleast one of the plurality of voids is at least partially filled with atleast one material having a density lower than, and a stretchabilitygreater than, that of the at least one polymer layer of the one or morepolymer layers.
 19. The cushion of claim 1, wherein at least one of theplurality of voids comprises a gas pocket, the gas pocket comprising atleast one of a gas release valve and at least one gas filling valve, andbeing filled with a gas selected from the group consisting of air,nitrogen, and argon.
 20. The cushion according to claim 1, wherein thebody support cushion is configured as a mattress, a body-support pad ora body-support mat.